Heat-transfer trussed-radiator



W. VV. ASTRUP ETAL HEAT-TRANSFER TRUSSED-RADIATOR Jan. l2, 1965 2 Sheets-Sheet 1 Filed April 9, 1962 FIG.

i i E i i i i i n i i i i i i i i i i i i n i i i I i i i i n i p i i INVENTORS: WlLLlAM ASTRUP DONALD W. CHRISTENSEN Jan# 12, 1965 w. v. ASTRUP ETAL 3,165,151

HEAT-TRANSFER TRussED-RADIATOR Filed April 9, 1962 2 Sheets-Sheet 2 INVENTORS: WILLIAM V. ASTRUP DONALD W. CHRISTENSEN ATT'Y.

United States Patent O 3 165,151 HEAT-TRANSFE TRUSSED-RADEATR William V. Astrup and Donald W. Christensen, Racine, Wis., assignors to Young Radiator Company, Racine, Wis., a corporation of Wisconsin l Filed Apr. 9, i962, Ser. No. 186,148 2 Claims. (Cl. 16S-Sl) This invention relates to heat exchangers of the type, generally designated radiators, wherein the fin-supported tubes have their ends bonded to perforate dish-like headers which are spanned by trussed, channel-shaped, protective and reinforcing side plates.

In radiators of this kind the core is made up of a battery of parallel, closely-spaced, tubes extending through and supporting closely-spaced, thin, transverse iin sheets. The ends of the tubes protrude beyond the opposite outermost iin sheets and are bonded to the perforate portions of the dish-type headers. The` dish-type header, it should be explained, is one where the major perforate portion is a rectangular-shaped depression offset by integral rims from an outwardly-extending, bordering, perimetrical ange disposed in a plane parallel with that of the perforate tube-supporting portion.

Generally, the tubes are made of copper or copper alloy and solder bonded to the headers which, as a rule, are made of brass. To provide a more rigid structure in such a radiator it has been a practice to arrange steel plates on opposite sides of the core. Usually, these side plates are channel-shaped and, as a rule, have had their ends bonded to the headers. In the interest of greater strength, brazing is the preferable form of bonding the side plate to the headers.

The soldering of the tube ends vto the headers and the brazing of the side plates to the headers always has presented a problem to the manufacturers of these radiators. The problem arises from ltwo facts: (l) soldering is done at temperatures approximately 500 F., whereas brazing is done at temperatures approximately 1200 F., and (2) it is more practical to braze the side plates to the headers after the tubes have been soldered to the headers. However, subjecting the previously, solder-bonded tubes, adjacent the header ends where the side plates are brazed, to the higher temperatures than required for solder bonding hazards the risk of melting some of the solder around the tubes and weakening,v if not breaking, the tube-end bonds to the headers.

To overcome this problem it recently became expedient to interpose gussets between the headers and the side Aserious leaks at the bonds of the tubes to the headers.

Obviously, this forced the supplier` to repair vor replace the defective units.

Studies and tests were undertaken to try to discover the cause of these all-too-frequent defects and a possible remedying thereof. Two facts were apparent. These locomotive radiators are comparatively massive and are subject to temperatures as high as 200 F. This led to the assumption that the expansion differential between the tubes bonded to the headers and the reinforcing side plates and the excessive vibration due to the high speeds at which these locomotives travel might be the primary causes for these recurring defects in the radiators.

The main objects of this invention, therefore, lare to provide an improved structuring of radiators which are subject to high-heat transfer and excessive vibration in normal use; to provide an improved form of floating connection of the reinforcing side plates to one of the headers to permit relative movement of the two headers as determined by the expansion characteristics of the battery of tubes bonded to the opposed headers; to provide an improved intertting relationship of the nested core-protective side plates and the reinforcing side plates to reduce to a minimum vibration that normally'tends to cause relative side-wise shifting of the finned tubes and the reinforcing side plates; to provide an improved trussed radiator of this kind comprising elements of such simple form and ease of assembly and bonding as to make for greater economy in production and longer service without repair or replacement of the units; and to provide a radiator of this structuring especially adapted for use in diesel. locomotives as currently used on railroads.

In the adaptation shown in the drawings:

FIG. l is a perspective view of a radiator constructed in accordance with this invention; i

FIG.` 2 is an exploded perspective of the two pairs of gussets which are bonded to the respective headers as shown in FIG. l;

FIG. 3 is an exploded perspective of portions of the several parts which assembled constitute a radiator constructed in accordance with this invention; and

FIG. 4 is an enlarged, fragmentary, transverse-sectional view at one side of this improved radiator taken on the plane of the line 4 4 of -FVIGQL The essential concept of this invention involves a radiator wherein the protective side plates are secured along the tube-supported iins and slidably nested in the reinforcing side plates which have one end of each bonded togussets in turn bonded -to one of the headers and the other end of each of which is .telescopically seated in the gussets bonded to the other header so as to permit relative movementof the headers under the strain ofheat expansion and contraction of the tubes and prevent relative sidewise shifting between the finned-tube core and the side-reinforcing plates. v

A radiator embodying the foregoing concept comprises ainned-tube core 5 supported on upper and lower headers 6 and 7 which fare spanned by reinforcing side plates 8 differently seated attheir opposite ends in opposite pairs of gussets 9 and 10.

The herein-designated core Sis a conventional unit comprising a batteryof tubes 11 held in closely-spaced parallel assembly by a plurality of `closely-spaced iin sheets 12 disposed radially 'of the'tubes '1l and having protective side plates 13 bonded along the opposite sides of such an assembly of tubes and fins. Such a structured coreY 5 vis shown and 'described in Patent No. 2,599,965.

As indicated in that patent and here the tubes 6 are of elongated or substantially elliptical form and are arranged in alternating staggered rows.

The, protective side plates t3, in this adaptation, are formed withtwo longitudinally-extending narrow, channelshaped offsets 14 along an opposite and wider median offset l5. These offsets 14 and l5 provide for nesting with the reinforcing side plates 8, as will be explained presently.

The upper and lower headers o and i are of identical form wherein the major apertured portion le, is offset by integral end and side rims l? and l@ from a bordering iiange 19 having a series of holes 2li for the reception of bolt-and-nut fasteners (not here shown) for mounting the radiator in operative position. Obviously, the plane of the apertured portion 16 is disposed parallel to the piane of the flange i9.

It should be noted here that upper and lowen strictly speaking, has reference primarily to the position in which the radiator is shown in FtG. l of the drawings. Morevoften than not, when used in diesel locomotives, these radiators are disposed horizontally. in that case the gussets would be referred to as used at one or the other end of the radiator.

The reinforcing side plates 8, as herein shown, in crosssection formsimulate an E by having the base part formed with a medial odset 22 disposed parallel with the perimetrical sides 23. This medial offset Z2 is dimensioned to snugly seat in the comparable medial offset l5 in a protective side plate i3 between the ofisets lll.

The gussets 9 and l@ are of short U-shape with the outer edges of the parallel wing parts Z-t disposed at an angle to the base part 25 and with each wing part 24- having a comparatively large circular opening 27. The lower pair of gussets 9 have groups of apertures 2d formed in the wings 2d and base 26 forreceivinglmobs of the bond- A ing material when this pair of gussets 6 are bonded to the freinforcing ently.

The pair of upper ygussets itl do not have these series ot apertures 2d, which are present inthe lower pair, for

side plates 3, as will be explained presjvery significant reason that the concept for structuring the herein shown radiator provides for the sliding seating oi the ends of the reinforcing side plates 8 in the pair of upper gussets iii. This is to permit a relative unrestrained movement of the headers e and toward and away from each other in response to the expansion-contraction which takes place in the tubes ,lll under the .changing temperatures at which these radiators function, especially when lused for 'cooling high-.heat engines such as the diesel locomotive. l l

it has been well-known that the thermal expansion differential between thecopper orcopper alloys et the tubes lll andthe steelof the reinforcing side plates 8, and the igussets'9 and` 1th when usedjis in the ratio of 1.50 to 1.00, respectively. Y However, heretofore, it has been assumed that'if. the reinforcing side-plates it were made of heavy enough material and were adequately bonded to the headfers 6 and 'I'this thermal expansion diiferential could not be the Vcauseforannoying' leales that too often occurred in these radiators when used on diesel locomotives.

j ljloweve'r, extended tests, antecedant to the concept for vthe' herein shownl telescopic relationship ofthe reinforced sidepplates Sand the upper pair of gussets 147i, vgave ample Y lreason `for believing that however firmly the reinforcing iside plates@ might be bonded to the header 6V and il this thermal expansion'differential between these conventionally used metals was, as a matter of fact, the primary cause for the fracturing of the bonds of the tubes ll to vthe headers and/ or '7 resulting in the annoying and expensive radiator leaks.

Therefore, in the 4herein-shown radiator, both pairs of gussets 93nd lll are bonded to the end and side rims l? and 1S of the respective headers @and 7. Preferably this bonding is a lconventional brazing operation. The lower ends of the 'reinforcing side plates 3 are bonded to the 4- respective gussets 9. ribis is effected by a conventional soldering operation.

The upper ends of the reinforcing side plates are seated in the upper pair of gussets itl, as the lower ends are seated in the lower gussets 9, but the upper ends are not bonded to the gussets lil. Thus this allowance for the relative shifting of the upper ends of the side plate 8 and the gussets i@ permits a relative movement oi the headers e and 7, axially of the tubes Iii, during the alternating expansion and contraction of these tubes under the changing temperature conditions to which the radiator is subiected inevitably.

Because of the high speeds at which these diesel locomotives travel, it has been assumed that the inevitable vibrations in the locomotive might be so communicated to the radiator as to cause some shifting of the core and the reinforcing side plates 8 transversely of the core 5. Such possible shifting, it has been assumed, might be a contributory cause to the radiator leaks. To insure against that possibility, the reinforcing side plates d and the core protective side plates i3 have been formed with the hereinshown respective offsets 22 and 14 and l5. These permit a hrm nesting of these sets of side plates S and i3 as shown in FIG. 4. Therefore, since the reinforcing side plates 3 have been so rmly secured to the headers d and 7 by means oi the gussets 9 and it?, this nesting of the opposite pairs of side plates S and l precludes any possibie sidewide movement of the core 5 within this supporting framework of the side plates il, the gussets 9 and l? and the headers and 7.

A radiator, constructed in accordance with this invention. is assembled in the following manner:

The core 5, with the tubes il and n sheets i2, is assembled in the conventional manner. The headers ti and and the gussets d and tti, liltewise, are formed in the usual manner. Moreover, the gussets 9 and itl are brazed in a conventional manner at the opposite ends of the respective headers i and 7.

The first step is to insert the tubes il, at one end of the core 5, into the apertures in one of the headers 6 or '7 and solder bond the tube end to the apertured depressed portion of the header.

Next the side plates S have one end of each inserted into the lower pair of gussets and soldered thereto in the conventional manner.

Then the other header has the apertured major portion set over the other ends of the tubes at the same time the other (Le. upper) ends of the side plates 8 are inserted into the other pair, (ie. upper) gussets it?. Thereupon, the other tube ends are solder bonded to the other header.

Variations and modifications in the details of the structure and arrangement of parts may be resorted to within the spirit and coverage of the appended claims.

I claim:

l. A heat-exchanger trussed-radiator comprising,

(a) a pair of apertured headers each having a bordering perimetrical ilange with the apertured portion of the header olfset from the plane of the bordering ange and defined by end'and side rims,

(b) a single battery of tubes arranged in closely-spaced parallel relationship and supporting a series of tins transversely-disposed in closely-spaced relationship with the opposite ends oi the tubes bonded in the apertured portion of the respective headers,

(c) pairs of U-shaped gussets each having the perimeters of the base and parallel wing parts bonded respectiveiy to the end and side rims oi the respective headers, and

(d) a pair of channel-shape reinforcing side piates eX- tending along the tube-supported tins on opposite sides thereof and each plate having one end bonded to the gussets on one header and each having the other end in sliding embracive contact with the gussets on the other header to permit movement of the headers relative to each other axially of the tubes in response to the alternating heat expansion-contraction of the tubes.

2. A heat-exchanger trussed-radiator as set forth in ciaim l out having in addition,

(e) a pair of protective plates each of channel shape embracively positioned and bonded along the opposite sides of the tube-supported ins and nesting within the respective reinforcing side plates, to secure the tube-supported fins against transverse shifting relative to the reinforcing side plates,

(f) the reinforcing side plates and the protective side plates having interiitting longitudinal portions oppositely oiset to rigidly retain the respective plates against relative shifting transversely thereof.

5 References Cited by the Exel* UNlTED STATES PATENTS 2,932,489 4/60 Young 165-149 2,933,291 4/60 Huggins 165-149 10 CHARLES SUKALO, Primary Examiner.

MEYER PERLEN, Examiner. 

1. A HEAT-EXCHANGER TRUSSED-RADIATOR COMPRISING, (A) A PAIR OF APERTURED HEADERS EACH HAVING A BORDERING PERIMETERICAL FLANGE WITH THE APERTURED PORTION OF THE HEADER OFFSET FROM THE PLANE OF THE BORDERING FLANGE AND DEFINED BY END AND SIDE RIMS, (B) A SINGLE BATTERY OF TUBES ARRANGED IN CLOSELY-SPACED PARALLEL RELATIONSHIP AND SUPPORTING A SERIES OF FINS TRANSVERSELY-DISPOSED IN CLOSELY-SPACED RELATIONSHIP WITH THE OPPOSITE ENDS OF THE TUBES BONDED IN THE APERTURED PORTION OF THE RESPECTIVE HEADERS, (C) PAIRS OF U-SHAPED GUSSETS EACH HAVING THE PERIMETERS OF THE BASE AND PARALLEL WING PARTS BONDED RESPECTIVELY TO THE END AND SIDE RIMS OF THE RESPECTIVE HEADERS, AND (D) A PAIR OF CHANNEL-SHAPED REINFORCING SIDE PLATES EXTENDING ALONG THE TUBE-SUPPORTED FINS ON OPPOSITE SIDES THEREOF AND EACH PLATE HAVING ONE END BONDED TO THE GUSSETS ON ONE HEADER AND EACH HAVING THE OTHER END IN SLIDING EMBRACIVE CONTACT WITH THE GUSSETS ON THE OTHER HEADER TO PERMIT MOVEMENT OF THE HEADERS RELATIVE TO EACH OTHER AXIALLY OF THE TUBES IN RESPONSE TO THE ALTERNATING HEAT EXPANSION-CONTRACTION OF THE TUBES. 